CN106574070B

CN106574070B - Microporous olefin film, method for producing same, separator for nonaqueous electrolyte secondary battery, and nonaqueous electrolyte secondary battery

Info

Publication number: CN106574070B
Application number: CN201580042724.5A
Authority: CN
Inventors: 菅田正美; 丰田直树
Original assignee: Toray Industries Inc
Current assignee: Toray Industries Inc
Priority date: 2014-08-12
Filing date: 2015-08-07
Publication date: 2019-12-17
Anticipated expiration: 2035-08-07
Also published as: JP6699552B2; KR20170041195A; EP3181622A4; JPWO2016024548A1; EP3181622B1; CN106574070A; US20170263906A1; WO2016024548A1; KR102344220B1; EP3181622A1; PL3181622T3; HUE053383T2; US10658640B2

Abstract

The invention provides a microporous membrane with excellent balance of temperature characteristic, shrinkage characteristic, permeability and strength, and further provides a separator for a non-aqueous electrolyte secondary battery and a non-aqueous electrolyte secondary battery with high performance and excellent safety. A polyolefin microporous membrane characterized in that the difference between the TD direction shutdown shrinkage temperature and the maximum shrinkage temperature measured by TMA is 7.2 ℃ or more, the difference between the TD direction shutdown shrinkage rate and the maximum shrinkage rate is less than 25%, the puncture strength is 400gf or more when the membrane thickness is 16 μm, and the ratio of the puncture strength to the air resistance is 2.0 to 4.0(gf/(sec/100cc)) when the membrane thickness is 16 μm.

Description

Microporous olefin film, method for producing same, separator for nonaqueous electrolyte secondary battery, and nonaqueous electrolyte secondary battery

Technical Field

The present invention relates to a polyolefin microporous film and a separator for a nonaqueous electrolyte secondary battery using the same, and more particularly, to a polyolefin microporous film having excellent safety and a separator for a nonaqueous electrolyte secondary battery using the same.

Background

In order to prevent an internal short circuit in a battery using a nonaqueous electrolytic solution such as a lithium ion battery, a separator having a shutdown function of shutting down a reaction at a time when a predetermined temperature is exceeded is essential. Generally, a battery separator is composed of a microporous membrane, and when the temperature rises, shrinkage occurs near the melting point, and the microporous membrane closes, thereby shutting down the battery reaction. When the temperature continues to rise further, the microporous membrane changes from contraction to elongation at a certain temperature, and finally the membrane is broken (blown).

The shutdown temperature can be expressed as a temperature at the inflection point of the sample length observed in the vicinity of the melting point in the TMA measurement (shutdown initiation temperature). When the microporous membrane does not have such an inflection point, shutdown and shrinkage proceed simultaneously at the time of temperature rise, and therefore it is difficult to sufficiently suppress a reaction at the time of occurrence of an abnormality. Therefore, from the viewpoint of safety, the microporous membrane for a separator preferably has the above-described inflection point. On the other hand, if the time from the start of closing to the closing of the hole is short, the energy may be released all at once when the fuse is once fused. Therefore, in order to gradually reduce the energy released upon occurrence of an abnormality, the shutdown temperature is preferably sufficiently lower than the maximum shrinkage temperature or the fusing temperature.

In the production process of a separator, orientation is widely imparted to the separator by stretching or the like to improve strength, and such a separator having orientation may exhibit anisotropy not only in strength but also in temperature characteristics such as shutdown temperature. Here, since the separator is usually wound in a state where tension is applied in the MD direction (machine direction), when the difference between the shutdown temperature in the TD direction (direction perpendicular to the machine direction, width direction) and the maximum shrinkage temperature is small, the film may shrink rapidly in the TD direction due to preheating, and a short circuit may easily occur at the end of the battery. In addition, when the shrinkage rate at the maximum shrinkage temperature (maximum shrinkage rate) is larger than the shrinkage rate at the shutdown temperature (shutdown shrinkage rate), the film may still shrink rapidly during shutdown. Therefore, from the viewpoint of safety, the shutdown temperature in the TD direction is preferably sufficiently lower than the maximum shrinkage temperature in the TD direction, and the difference between the shutdown shrinkage rate in the TD direction and the maximum shrinkage rate is preferably small.

As a method for controlling the anisotropy, for example, patent document 1 describes that the anisotropy of a microporous membrane is controlled by simultaneously performing biaxial stretching at different magnifications. However, although the difference between the shutdown temperature and the maximum shrinkage temperature of the microporous membrane obtained by this method is large, the maximum shrinkage rate tends to increase, and rapid shrinkage may occur at high temperatures. In addition, in such a stretching method, it is difficult to greatly improve the strength of the microporous membrane.

In contrast, as another method, there is a method of improving the properties of a microporous membrane by controlling the components of the microporous membrane. For example, patent document 2 describes a method for producing a microporous membrane using a mixture of polyethylene having a low melting point and capable of lowering the shutdown temperature and polypropylene useful for maintaining the membrane state at a high temperature. However, in the method of blending polyethylene and polypropylene, polyethylene and polypropylene are incompatible, and therefore, a sea-island structure is easily formed, and physical unevenness is easily generated, and thus it is difficult to obtain sufficient shutdown characteristics.

In addition, from the viewpoint of battery performance, the permeability of the separator is preferably high, but when the strength is greatly reduced with the improvement of permeability, the separator is likely to break, and the safety may be lowered. Therefore, in the secondary battery separator, it is preferable to combine high output of a battery having high permeability and safety due to increased strength at a high level.

[ Prior art documents ]

[ patent document ]

Patent document 1: japanese patent laid-open No. 2010-007053.

Patent document 2: japanese patent laid-open No. 6-096753.

Disclosure of Invention

[ problems to be solved by the invention ]

Accordingly, an object of the present invention is to provide a microporous membrane having an excellent balance among temperature characteristics, shrinkage characteristics, permeability and strength, and to provide a separator for a nonaqueous electrolyte secondary battery and a nonaqueous electrolyte secondary battery having high performance and excellent safety.

[ means for solving problems ]

in order to solve the above problem, the present invention has any one of the following configurations.

(1) A polyolefin microporous membrane characterized in that the difference between the TD direction shutdown shrinkage temperature and the maximum shrinkage temperature measured by TMA is 7.2 ℃ or more, the difference between the TD direction shutdown shrinkage rate and the maximum shrinkage rate is less than 25%, the puncture strength is 400gf or more when the membrane thickness is 16 μm, and the ratio of the puncture strength to the air resistance is 2.0 to 4.0(gf/(sec/100cc)) when the membrane thickness is 16 μm.

(2) The polyolefin microporous membrane according to (1), characterized in that the porosity is 45% or more.

(3) The polyolefin microporous membrane according to (1) or (2), wherein the polyolefin microporous membrane has a molecular weight of 5.0X 10⁵The polyolefin content is 63 wt% or less, and the molecular weight is 1.0X 10⁶The content of the above polyolefin is 21% by weight or more.

(4) The polyolefin microporous membrane according to any one of (1) to (3), wherein the weight-average molecular weight is 1.0X 10⁶The content of the above ultrahigh molecular weight polyolefin is 15 to 45% by weight.

(5) A method for producing a polyolefin microporous membrane according to any one of the above (1) to (4), comprising the following steps (a) to (f).

(a) For the weight average molecular weight of 1.0X 10⁶And a step of melt-kneading the polyolefin resin of the ultrahigh molecular weight polyethylene and the plasticizer to prepare a polyolefin solution.

(b) And (b) extruding the polyolefin solution obtained in the step (a) by an extruder to form an extrudate, cooling the extrudate, and molding the extrudate into a gel sheet.

(c) Stretching the sheet obtained in the step (b) in a longitudinal direction (machine direction).

(d) And (c) a step of stretching the sheet obtained in the step (c) in a horizontal direction (a direction perpendicular to the machine direction) continuously to the step (c).

(e) And (d) extracting the plasticizer from the stretched film obtained in step (d).

(f) And (e) drying the film obtained in step (e).

(6) A separator for a nonaqueous electrolyte secondary battery, comprising the polyolefin microporous membrane according to any one of (1) to (4).

(7) A nonaqueous electrolyte secondary battery comprising the separator for nonaqueous electrolyte secondary batteries according to (6).

[ Effect of the invention ]

According to the polyolefin microporous membrane of the present invention, since the difference between the shutdown shrinkage temperature and the maximum shrinkage temperature in the TD direction is large and the difference between the shutdown shrinkage rate and the maximum shrinkage rate in the TD direction is small, the polyolefin microporous membrane can be gradually shrunk at a high temperature to gradually release energy. Further, the microporous membrane has high puncture strength and a ratio of puncture strength to air resistance in a predetermined range, and therefore has an excellent balance between strength and permeability. Therefore, by using such a microporous membrane, a highly safe separator for a nonaqueous electrolyte secondary battery having excellent shutdown characteristics can be obtained.

Further, by appropriately adjusting the molecular weight distribution of the polyolefin, the anisotropy can be controlled, and the shutdown characteristics of the microporous membrane can be improved. In particular, by using an appropriate amount of the ultrahigh molecular weight polyolefin, it is possible to achieve both high strength and excellent shutdown properties.

Further, in the conventional method for producing a microporous membrane, the improvement in strength is often in a trade-off relationship with the improvement in shutdown characteristics. In contrast, in the present invention, by performing successive stretching by a predetermined method, a microporous membrane having excellent temperature characteristics in the TD direction and high strength can be obtained.

As described above, according to the present invention, a separator for a nonaqueous electrolyte secondary battery having excellent strength, permeability, and safety can be obtained, and as a result, a battery having high performance and excellent safety can be realized as compared with the conventional battery.

Drawings

Fig. 1 is a schematic diagram for explaining the main contents of the measurement results of TMA (thermo-mechanical analyzer).

FIG. 2 is a schematic view showing an example of a molecular weight distribution curve of polyolefin.

Detailed Description

Preferred embodiments of the present invention will be described below.

The polyolefin microporous membrane of the present invention is characterized in that the difference between the shutdown shrinkage temperature in the TD direction measured by TMA (thermal mechanical analysis) and the maximum shrinkage temperature is 7.2 ℃ or more, preferably 8.6 ℃ or more. Fig. 1 is a schematic diagram showing the measurement result of TMA. In the TD directionThe off shrinkage temperature of (a) is a temperature at which the shrinkage rate in the TD direction (first derivative of the temperature based on the length in the TD direction) has an extreme value near the melting point when the temperature of the length in the TD direction of the sample is measured using TMA, in other words, a temperature at the inflection point of the length in the TD direction, and is T in fig. 1₁. The maximum shrinkage temperature in the TD direction is a temperature at which the length of the sample in the TD direction is minimum, and is T in fig. 1₂. The temperature difference is small (i.e., T)₂-T₁Small) and the shutdown current is used, the film is shrunk in the TD direction by preheating, and therefore, there is a possibility that short circuit between electrodes is easily caused at the end of the battery at high temperature. The difference between the shutdown shrinkage temperature in the TD direction and the maximum shrinkage temperature is large, so that the time from the shutdown to the start of shrinkage of the film in the TD direction becomes long, and shrinkage is less likely to occur even when heated in an abnormal state, and a microporous film having excellent safety can be obtained. In addition, since the difference between the shutdown shrinkage temperature in the TD direction and the maximum shrinkage temperature is large, even if the microporous membrane shrinks, the dimensional change in the width direction is slow, and therefore, energy can be released slowly from the end portions of the microporous membrane, and excellent safety can be achieved. The maximum value of the industrially achievable temperature difference (difference between the shutdown shrinkage temperature and the maximum shrinkage temperature in the TD direction) is about 15 ℃. Therefore, the difference between the off-shrinkage temperature and the maximum shrinkage temperature in the TD direction is preferably 7.2 to 15 ℃, and more preferably 8.6 to 15 ℃.

In the polyolefin microporous membrane of the present invention, the difference between the shutdown shrinkage rate in the TD direction and the maximum shrinkage rate is less than 25%. Here, the TD shrinkage ratio is the TD shrinkage ratio of the microporous membrane at the TD shrinkage temperature in the shutdown direction, and is calculated based on the TD length at room temperature. The maximum shrinkage in the TD direction is the TD shrinkage of the microporous membrane at the maximum shrinkage temperature in the TD direction, and is calculated based on the TD length at room temperature. The difference between the shutdown shrinkage rate and the maximum shrinkage rate is reduced, whereby the shrinkage of the film after shutdown is reduced, and short-circuiting is less likely to occur, and therefore, the film is excellent in safety. In addition, in view of safety, a shutdown function is essential, and the pores are closed during shutdown, and therefore shrinkage of the microporous membrane is inevitably caused. Therefore, it is necessary to anticipate the shrinkage of the film due to shutdown in the design of the battery, and when the maximum shrinkage rate is too large relative to the shutdown shrinkage rate, the size of the separator must be designed taking this into consideration, which is not preferable from the viewpoint of cost. The minimum value of the difference in shrinkage ratio (difference between the off shrinkage ratio and the maximum shrinkage ratio) that can be achieved industrially is about 10%, and from the viewpoint of safety, it is preferable that the difference in shrinkage ratio is as small as possible, and the lower limit of the difference in shrinkage ratio is not particularly limited. Therefore, the difference between the off shrinkage rate and the maximum shrinkage rate is preferably in the range of 10% to 25%.

From the viewpoint of improving durability, the puncture strength of the microporous membrane is preferably 400gf or more when the membrane thickness is 16 μm. Here, the puncture strength when the film thickness is 16 μm means that the film thickness is T₁The puncture strength (maximum load) of the microporous membrane (μm) was L₁Then, from the formula: l is₂＝(L₁×16)/T₁calculated puncture strength L₂. In the present specification, unless otherwise specified, the term "puncture strength" is used in the meaning of "puncture strength when the film thickness is set to 16 μm". The maximum value of the puncture strength industrially achievable is about 800gf, and the puncture strength is preferably as large as possible from the viewpoint of durability, and the upper limit of the puncture strength is not particularly limited. Therefore, the puncture strength is preferably in the range of 400gf to 800 gf.

From the viewpoint of safety, the gas barrier length is preferably 100sec/100cc or more when the film thickness is 16 μm. Here, the gas resistance when the film thickness is 16 μm means that the film thickness is T₁(μm) the puncture strength of the microporous membrane measured according to JIS P8117 (2009) is P₁Then, from the formula: p₂＝(P₁×16)/T₁Calculated puncture strength P₂. In this specification, the term "film" is used only for the filmThe thickness is not particularly described, and the term "air resistance" is used in the meaning of "air resistance when the film thickness is 16 μm". If the gas resistance is less than 100sec/100cc, the shutdown before the fusing may not be sufficiently performed when the temperature in the battery increases. From the viewpoint of the balance between battery output and safety, the upper limit of the gas resistance is preferably 400sec/100cc or less. Therefore, the gas resistance is preferably in the range of 100sec/100cc to 400sec/100 cc.

From the viewpoint of balancing the battery output and safety, the ratio of puncture strength to air resistance when the film thickness is 16 μm { (puncture strength when the film thickness is 16 μm)/(air resistance when the film thickness is 16 μm) } is preferably within a range of 2.0 to 4.0(gf/(sec/100 cc)). When the ratio of the puncture strength to the air resistance is within the above range, the high output of the battery with high permeability and the safety with high strength can be achieved at the same time.

From the viewpoint of permeability and electrolyte content, the porosity is preferably 35% or more. When the lower limit of the porosity is in the above range, the output of the battery can be improved, and the battery is preferably used for the higher capacity of the battery which is likely to be developed in the future. From the viewpoint of securing strength, the upper limit of the porosity is preferably 60%. Therefore, the porosity is preferably 35% to 60%.

The microporous membrane material preferably contains a polyolefin component having a molecular weight of 50 ten thousand or less in an amount of 63 wt% or less, based on 100 wt% of the polyolefin as a whole. When the content of the polyolefin component having a molecular weight of 50 ten thousand or less is more than 63% by weight, not only the shutdown shrinkage temperature but also the maximum shrinkage temperature are lowered, and it is difficult to secure the strength of the microporous membrane. The lower limit of the content of the polyolefin component having a molecular weight of 50 ten thousand or less is preferably 45 weight percent or more, assuming that the whole polyolefin is 100 weight percent. Therefore, the content of the polyolefin component having a molecular weight of 50 ten thousand or less based on the entire weight of the polyolefin is preferably 45% to 63%.

The content of the polyolefin component having a molecular weight of 100 ten thousand or more is preferably 21 weight percent or more, assuming that the whole polyolefin is 100 weight percent. By setting the content of the polyolefin component having a molecular weight of 100 ten thousand or more to 21 weight percent or more, excellent strength can be obtained, and a decrease in the maximum shrinkage temperature due to the addition of a low-molecular-weight polyolefin can be prevented, so that both strength and safety can be achieved at a high level. The upper limit of the content of the polyolefin component having a molecular weight of 100 ten thousand or more is preferably 40 weight% or less when the polyolefin is 100 weight% as a whole. Therefore, the content of the polyolefin component having a molecular weight of 100 ten thousand or more based on the entire weight of the polyolefin is preferably 21% to 40%.

The molecular weight distribution of the polyolefin can be determined by a method such as GPC (gel permeation chromatography) analysis. FIG. 2 is a schematic diagram showing a molecular weight distribution curve of polyethylene obtained by GPC, wherein the horizontal axis represents a logarithmic value of molecular weight, and the vertical axis represents a value obtained by differentiating a concentration fraction of polyolefin by a logarithmic value of molecular weight. In fig. 2, the region (represented by molecular weight distribution curve, "M ═ 5.0 × 10⁵The region surrounded by a dotted line extending from the lower side of the mark toward the horizontal axis and the horizontal axis ") corresponds to the" polyolefin component having a molecular weight of 50 ten thousand or less ", and the region (b) (defined by the molecular weight distribution curve," M ═ 1.0 × 10⁶The area surrounded by a dotted line extending from the lower side of the mark toward the horizontal axis and the horizontal axis) corresponds to "a polyolefin component having a molecular weight of 100 ten thousand or more".

In the production of a polyolefin microporous membrane, usually, a plurality of polyolefins having different polymer components and weight average molecular weights are used, and the properties of the microporous membrane can be improved by adjusting the amounts of the respective polyolefins added. Therefore, in the present invention, the weight average molecular weight is 1.0X 10 when the polyolefin is 100 weight percent as a whole⁶the amount of the above ultrahigh molecular weight polyolefin is preferably 15 to 45% by weight. By setting the amount of the ultrahigh-molecular-weight polyolefin to 15 weight percent or more, excellent strength can be obtained, and a decrease in the fusing temperature and the maximum shrinkage temperature due to the addition of the low-molecular-weight polyolefin can be prevented, so that both strength and safety can be achieved at a high level. In addition, by making the super highThe amount of the polyolefin added is 45% by weight or less, and a decrease in flowability during extrusion molding and a decrease in stretchability during film formation can be prevented.

as mentioned above, the weight average molecular weight of 1.0X 10 was used⁶In the case of the above ultrahigh-molecular-weight polyolefin, the molecular weight distribution (ratio of the weight-average molecular weight Mw to the number-average molecular weight Mn, i.e., Mw/Mn) of the ultrahigh-molecular-weight polyolefin is preferably in the range of 3 to 20. When the molecular weight distribution is too narrow, the amount of high molecular weight components increases, and the flowability in extrusion molding decreases. In addition, the film may be broken due to a decrease in stretchability during film formation. On the other hand, if the molecular weight distribution is too broad, the proportion of low molecular weight components increases, and it may be difficult to secure strength.

The kind of polyolefin as a material of the microporous membrane is not particularly limited as long as the target microporous membrane can be obtained, and polyethylene is preferably used.

The method for producing a polyolefin microporous membrane preferably includes the following steps (a) to (f).

(f) And (e) drying the film obtained in step (e).

By carrying out the steps (a) to (f) in the production of the microporous membrane, a microporous membrane suitable for a nonaqueous electrolyte secondary battery separator can be obtained. First, by using an ultrahigh molecular weight polyolefin, a microporous membrane having excellent strength and a high maximum shrinkage temperature can be obtained. In the absence of the ultrahigh molecular weight component, the shape retaining effect up to high temperatures cannot be obtained by the ultrahigh molecular weight component. Further, since the network of the molecular chain based on the ultrahigh molecular weight component is not uniformly configured, uneven deformation is easily caused particularly in sequential stretching, and a high MD stretching ratio is required for uniform stretching. As a result, the orientation in the TD direction is easily deteriorated, and the maximum shrinkage temperature in the TD direction is easily lowered. However, when the amount of the ultrahigh molecular weight component is too large, the film formation may be unstable due to a decrease in flowability and stretchability, and therefore, the amount of the ultrahigh molecular weight polyolefin to be added is preferably within the above range.

Further, by performing sequential stretching, a microporous membrane having excellent permeability and strength can be realized. In the present invention, the stretching in the longitudinal direction in the step (c) (hereinafter, sometimes abbreviated as "MD stretching") and the stretching in the horizontal direction in the step (d) (hereinafter, sometimes abbreviated as "TD stretching") are continuously performed, whereby the following excellent effects can be obtained. First, by increasing the TD stretching ratio, the TD orientation can be improved, and the shrinkage temperature at high temperatures can be increased. In addition, since the stretching temperature in the MD direction and the stretching temperature in the TD direction can be changed in the sequential stretching, it is possible to achieve both the improvement of the strength by the MD stretching and the improvement of the shutdown characteristics by the TD stretching (that is, the expansion of the difference between the shutdown shrinkage temperature and the maximum shrinkage temperature) by appropriately adjusting the temperatures. Further, by adopting the sequential stretching method, orientation can be efficiently performed as compared with simultaneous biaxial stretching, and high strength can be further achieved. The "continuous" means that the step (d) is continuously performed after the step (c), and thus there is no other step (for example, a heat treatment step, a cooling step, or the like) between the step (c) and the step (d). Therefore, in the present invention, the microporous membrane is stretched in the steps (c) and (d) by disposing a longitudinal stretcher for stretching the gel sheet in the longitudinal direction and a horizontal stretcher for stretching the gel sheet in the horizontal direction adjacent to each other in the production direction of the microporous membrane (the direction from the extruder side toward the microporous membrane winding side), and continuously stretching the microporous membrane using these longitudinal stretcher and horizontal stretcher.

Preferred embodiments of the above-described production method will be specifically described below.

< Process (a) > production of polyolefin solution

In the step (a), a polyolefin solution is prepared by heating and dissolving a polyolefin resin in a plasticizer. The plasticizer is not particularly limited as long as it is a solvent capable of sufficiently dissolving the polyolefin. In order to enable higher-magnification stretching, the solvent is preferably liquid at room temperature. Examples of the liquid solvent include aliphatic, cyclic aliphatic or aromatic hydrocarbons such as nonane, decane, decalin, p-xylene, undecane, dodecane and liquid paraffin, mineral oil fractions having boiling points corresponding to those of the hydrocarbons, and phthalic acid esters which are liquid at room temperature such as dibutyl phthalate and dioctyl phthalate. In order to obtain a stable gel sheet with little change in the content of the liquid solvent, it is preferable to use a nonvolatile liquid solvent such as liquid paraffin. The polyolefin may be mixed in a melt-kneaded state, or a solid solvent may be mixed into the liquid solvent at room temperature. Examples of such solid solvents include stearyl alcohol, wax alcohol, and paraffin. However, since the use of only a solid solvent may cause uneven stretching, it is preferable to use the solid solvent in combination with a liquid solvent.

The compounding ratio of the polyolefin resin and the plasticizer is preferably 10 to 50% by weight, more preferably 20 to 40% by weight, and still more preferably 20 to 35% by weight, based on 100% by weight of the total amount of the polyolefin resin and the plasticizer, from the viewpoint of improving the moldability of the extrudate. The lower limit of the polyolefin resin content is particularly preferably 20 weight percent. The upper limit is particularly preferably 40 weight percent, more preferably 35 weight percent. When the content of the polyolefin resin is 10% by weight or more, the expansion and the retraction at the die exit are small when the sheet is formed, and therefore the sheet formability and the film forming property are good. When the content of the polyolefin resin is 50 wt% or less, the shrinkage in the thickness direction is small, and therefore, the moldability and the film-forming property are good. Within this range, the puncture strength and the air resistance can be easily combined by the film forming method described later, and the friction coefficient of the front and back surfaces of the film can be controlled.

The viscosity of the liquid solvent is preferably 20 to 200cSt at 40 ℃. When the viscosity at 40 ℃ is set to 20cSt or more, the sheet obtained by extruding the polyolefin solution from the die is less likely to be uneven. On the other hand, when the concentration is 200cSt or less, the liquid solvent is easily removed.

< procedure (b-1) > formation of extrudate

The method and apparatus for melt-kneading the polyolefin solution are not particularly limited as long as they can uniformly melt-knead the polyolefin solution, but when it is desired to prepare a polyolefin solution having a high concentration, it is preferably carried out in an extruder, particularly preferably in a twin-screw extruder. Various additives such as an antioxidant may be added as necessary within a range not impairing the effects of the present invention. In particular, in order to prevent oxidation of polyethylene, it is preferable to add an antioxidant.

In the extruder, the polyolefin solution is uniformly mixed at a temperature at which the polyolefin resin is completely melted. The melt kneading temperature varies depending on the polyolefin resin used, but the lower limit is preferably (melting point of polyolefin resin +10 ℃ C.), more preferably (melting point of polyolefin resin +20 ℃ C.), and most preferably (melting point of polyolefin resin +40 ℃ C.). The upper limit is preferably (melting point of polyolefin resin +120 ℃ C.), more preferably (melting point of polyolefin resin +100 ℃ C.), and most preferably (melting point of polyolefin resin +70 ℃ C.). Therefore, the mixing temperature in the extruder is preferably (melting point of polyolefin resin +10 ℃) to (melting point of polyolefin resin +120 ℃), more preferably (melting point of polyolefin resin +20 ℃) to (melting point of polyolefin resin +100 ℃), and most preferably (melting point of polyolefin resin +40 ℃) to (melting point of polyolefin resin +70 ℃). Here, the melting point refers to a value measured by DSC (differential scanning calorimetry) according to JIS K7121(1987) (the same applies hereinafter). For example, when the melting point of the polyethylene composition is usually about 130 to 140 ℃ and the melting point of the polyolefin composition to be used is 130 ℃, the lower limit of the melt kneading temperature is preferably 140 ℃, more preferably 150 ℃, and most preferably 170 ℃. The upper limit is preferably 250 ℃, more preferably 230 ℃, and most preferably 200 ℃. Accordingly, the melt-kneading temperature when a polyethylene composition having a melting point of 130 ℃ is used is preferably 140 to 250 ℃, more preferably 150 to 230 ℃, and most preferably 170 to 200 ℃.

When polypropylene is contained in the polyolefin solution, the melt kneading temperature is preferably 190 to 270 ℃.

The melt kneading temperature is preferably low in order to suppress deterioration of the resin, but if the temperature is lower than the above temperature, an unmelted product is generated in the extrudate extruded from the die, and film breakage or the like is caused in the subsequent stretching step, and if the temperature is higher than the above temperature, thermal decomposition of the polyolefin is severe, and there is a possibility that the physical properties of the obtained microporous membrane, for example, puncture strength, tensile strength or the like, are deteriorated.

In order to obtain good processing and kneading properties and resin dispersibility/distributability, the ratio (L/D) of the screw length (L) to the diameter (D) of the twin-screw extruder is preferably 20 to 100. The lower limit is more preferably 35. The upper limit is more preferably 70. When the L/D is 20 or more, the melt kneading is sufficient. When the L/D is 100 or less, the residence time of the polyolefin solution is not excessively prolonged. The twin-screw extruder preferably has a cylinder inner diameter of 40 to 100mm in order to prevent deterioration of the resin to be kneaded and to obtain good dispersibility and dispersibility.

In order to achieve good dispersion of polyethylene in the extrudate and excellent uniformity of the thickness of the microporous film, the screw rotation speed (Ns) of the twin-screw extruder is preferably 150 to 600 rpm. Further, it is preferable that the ratio Q/Ns of the extrusion amount Q (kg/h) of the polyolefin solution to Ns (rpm) is 0.6kg/h/rpm or less. More preferably 0.35kg/h/rpm or less.

The melt-kneaded polyolefin solution is extruded directly from a die by an extruder or further extruded from a die via another extruder, and molded so that the thickness of the microporous membrane of the final product is 5 to 100 μm, thereby obtaining an extrudate. The die may use a rectangular T-die. When a T die is used, the slit gap of the die is preferably 0.1 to 5mm from the viewpoint of easy control of the thickness of the microporous membrane of the final product, and the die is preferably heated to 140 to 250 ℃ during extrusion.

< step (b-2) > Molding of colloidal sheet

By cooling the extrudate obtained, a gel-like sheet is obtained, by which the microphase of the polyethylene separated by the solvent can be fixed. In the cooling step, the temperature is preferably cooled to a temperature not higher than the crystallization completion temperature. The cooling is preferably performed at a rate of 250 ℃/min or less, more preferably at a rate of 300 ℃/min, on both the front and back surfaces of the gel sheet, to the crystallization completion temperature or less. When the cooling rate is in the above range, the crystals forming the gel are not coarsened and a dense aggregate structure can be obtained, and therefore, the surface roughness is less likely to be uneven. Further, since the aggregate structure is fine, the molecular orientation is easily performed in the subsequent stretching, and the puncture strength, the air resistance, and the friction coefficient can be controlled at the same time. Here, the crystallization completion temperature is an extrapolated crystallization completion temperature measured in accordance with JIS K7121 (1987). Specifically, polyethylene has an extrapolated crystallization completion temperature of about 70 to 90 ℃. The cooling rate here can be determined from the time from the temperature of the resin at the extruder outlet to the crystallization completion temperature and the temperature difference between the temperature of the resin at the extruder outlet and the crystallization completion temperature. Therefore, when the resin is cooled to a temperature not higher than the crystallization completion temperature in the cooling step, the difference between the resin temperature at the extruder outlet and the gel sheet temperature on the front and back surfaces of the cooling step outlet is divided by the time passed through the cooling step. A microporous film having a coefficient of static friction of 0.5 to 1.0 when the front and back surfaces of the film are superposed can be obtained by controlling the cooling rate of one surface (front surface) and the cooling rate of the other surface (back surface) of the gel sheet.

As a method for cooling the extrudate, there are a method of directly contacting the extrudate with cold air, cooling water, or another cooling medium, a method of contacting the extrudate with a roller cooled with a refrigerant, a method using a casting drum, and the like. The solution extruded from the die is extracted at a predetermined extraction ratio before or during cooling, and the lower limit of the extraction ratio is preferably 1 or more. The upper limit is preferably 10 or less, more preferably 5 or less. When the draw-out ratio is 10 or less, the draw-in becomes small, and the breakage is hardly caused during the drawing.

The lower limit of the thickness of the gel sheet is preferably 0.5mm, more preferably 0.7 mm. The upper limit of the thickness is 3mm, more preferably 2 mm. When the thickness of the colloidal sheet is 3mm or less, structural unevenness is less likely to occur in the thickness direction in the cooling process, the aggregated structure can be made compact in the thickness direction as a whole, and the structures on both the front and back sides can be kept compact. When the thickness of the jelly sheet is 3mm or less, the cooling rate of the jelly sheet is easily set to the above-described preferable range.

The case where the microporous film is a single layer has been described so far, but the polyolefin microporous film of the present invention is not limited to a single layer, and may be a laminate in which several microporous films (layers) are further laminated. The additional laminated layer may contain a desired resin in addition to the polyethylene as described above to the extent that the effects of the present invention are not impaired. As a method for forming the polyolefin microporous membrane into a laminate, a conventional method can be used, and for example, the following methods can be used: if necessary, desired resins are prepared, and these resins are supplied to an extruder, melted at a desired temperature, merged in a polymer pipe or a die, and extruded from a slit die at a target lamination thickness to form a laminate.

< Processes (c) and (d) > stretching

In the present invention, the following successive stretching is performed: the obtained gel sheet is stretched in the longitudinal direction (mechanical direction) (step (c)), and then continuously stretched in the horizontal direction (direction perpendicular to the mechanical direction) (step (d)). By independently and continuously performing the longitudinal stretching and the horizontal stretching in this manner, it is possible to achieve both the puncture strength and the air resistance, and further to easily obtain a predetermined friction coefficient. Stretching is heating the gel sheet, and stretching is performed at a predetermined magnification by a general tenter method, a roll method, or a combination of these methods.

In the stretching method of the present invention, since the longitudinal stretching and the horizontal stretching are performed separately, the stretching tension is applied only in each direction in each stretching step, and the molecular orientation is easily performed. Therefore, compared to simultaneous stretching, the molecular orientation can be improved even at the same area magnification, and high puncture strength can be achieved.

The stretch ratio varies depending on the thickness of the gel sheet, and it is preferably 5 times or more in any direction. The stretching in the longitudinal direction is preferably performed at 5 times or more, more preferably at 7 times or more. The upper limit of the longitudinal stretching is preferably 12 times, and more preferably 10 times. If the stretching in the longitudinal direction is 5 times or more, high strength can be imparted by the stretching orientation. Further, if the ratio is 12 times or less, the occurrence of breakage due to stretching is difficult. Therefore, the stretch ratio in the longitudinal direction is preferably 5 to 12 times, and more preferably 7 to 10 times.

The stretching in the horizontal direction (width direction) is preferably performed at 4 times or more, and more preferably at 6 times or more. The upper limit of the magnification of the transverse stretching is preferably 10 times, and more preferably 8 times. If the stretching in the horizontal direction is 4 times or more, higher strength can be imparted by the stretching orientation. Further, if the ratio of the transverse stretching is 10 times or less, the occurrence of cracks due to stretching becomes difficult, and the surface can be prevented from being deformed into irregularities and being smoothed due to the stretching of the film. Therefore, the ratio of the transverse stretching is preferably 4 to 10 times, more preferably 6 to 8 times.

In the area magnification combining the longitudinal stretching and the horizontal stretching, the area magnification is preferably 25 times or more, particularly preferably 30 times or more, and most preferably 42 times or more. The upper limit is not particularly limited, and is preferably 120 times or less from the viewpoint of preventing membrane rupture. The area magnification is preferably 25 times to 120 times, more preferably 30 times to 120 times, and further preferably 42 times to 120 times.

The stretching temperature is preferably equal to or lower than the melting point of the polyolefin resin, and more preferably in the range of (the crystal dispersion temperature Tcd of the polyolefin resin) to (the melting point of the polyolefin resin). If the stretching temperature is not higher than the melting point of the gel sheet, the polyolefin resin can be prevented from melting, and the molecular chains can be efficiently oriented by stretching. Further, if the stretching temperature is not lower than the crystal dispersion temperature of the polyolefin resin, the polyolefin resin is sufficiently softened and the stretching tension is low, so that the film forming property is good, and the film is not easily broken during stretching, and high-ratio stretching can be performed. The stretching temperature in the step (c) and the stretching temperature in the step (d) may be the same or different from each other.

Specifically, in the case of a polyethylene resin, the stretching temperature is preferably 80 ℃ or higher because the polyethylene resin has a crystal dispersion temperature of about 80 to 100 ℃. The upper limit of the stretching temperature is preferably 130 ℃, more preferably 125 ℃, and most preferably 120 ℃. Therefore, the stretching temperature when the polyethylene resin is used is preferably 80 to 130 ℃, more preferably 80 to 125 ℃, and still more preferably 80 to 125 ℃. The crystal dispersion temperature Tcd can be determined from the temperature characteristics of dynamic viscoelasticity measured according to ASTM D4065. Alternatively, it can be determined by NMR.

The aggregated structure formed into a gel-like sheet by the above stretching is cracked, and the crystal phase is refined to form numerous fibrils. The fibrils form a three-dimensional irregularly connected network structure. The stretching improves the mechanical strength and enlarges the pores, and therefore, the separator is suitable for a battery separator.

In the present invention, it is important that the sequential stretching is performed before the plasticizer of the gel sheet is removed. When a sufficient amount of the plasticizer is contained in the gel sheet, the polyolefin is in a sufficiently plasticized and softened state, and therefore, the aggregate structure is smoothly cracked by stretching before the plasticizer is removed, and the refinement of the crystal phase can be uniformly performed.

< step (e) > extraction of plasticizer from stretched film (cleaning)

Next, the solvent remaining in the gel sheet is extracted and removed with a cleaning solvent, that is, the gel sheet is cleaned. The polyolefin phase is separated from the solvent phase, and thus by removing the solvent, a microporous membrane can be obtained. Examples of the cleaning solvent include saturated hydrocarbons such as pentane, hexane and heptane, chlorinated hydrocarbons such as dichloromethane and carbon tetrachloride, ethers such as diethyl ether and dioxane, ketones such as methyl ethyl ketone, ethane trifluoride and C₆F₁₄、C₇F₁₆Isochain fluorocarbon, C₅H₃F₇Iso-cyclic hydrofluorocarbons, C₄F₉OCH₃、C₄F₉OC₂H₅Isohydrofluoroether, C₄F₉OCF₃、C₄F₉OC₂F₅And other volatile solvents such as perfluoroethers. These cleaning solvents have a low surface tension (e.g., 24mN/m or less at 25 ℃). By using a cleaning solvent having a low surface tension, a microporous membrane can be obtained which has a high porosity and permeability, in which shrinkage is suppressed by the surface tension of the gas-liquid interface during drying after cleaning a network structure forming micropores. These cleaning solvents are appropriately selected depending on the solvent used for the dissolution of the polyolefin resin, and used alone or in combination.

The washing method may be a method of immersing the gel sheet in a washing solvent and extracting the gel sheet, a method of spraying a washing solvent onto the gel sheet, a method of combining these methods, or the like. The amount of the cleaning solvent used varies depending on the cleaning method, and is usually preferably 300 parts by weight or more based on 100 parts by weight of the gel sheet. The cleaning temperature can be 15-30 ℃, and can also be heated to more than 80 ℃ according to needs. In this case, from the viewpoint of improving the cleaning effect of the solvent, from the viewpoint of preventing the properties of the microporous membrane in the horizontal direction and/or the longitudinal direction from becoming uneven among the properties of the obtained microporous membrane, and from the viewpoint of improving the mechanical properties and the electrical properties of the microporous membrane, the longer the time for which the gel sheet is immersed in the cleaning solvent, the better.

The washing as described above is preferably performed until the washed gel sheet is obtained, that is, the residual solvent in the microporous membrane is less than 1% by weight.

< step (f) > drying of microporous film

After washing, the microporous membrane is dried and the washing solvent is removed. The drying method is not particularly limited, and drying can be performed by, for example, a heat drying method, an air drying method, or the like. The drying temperature is preferably not more than the crystal dispersion temperature Tcd of the polyethylene composition, and particularly preferably not more than (Tcd-5 ℃). When the dry weight of the microporous membrane is 100 wt%, the drying is preferably performed until the residual cleaning solvent is 5 wt% or less, and more preferably, the drying is performed until 3 wt% or less. If the drying is insufficient, the porosity of the microporous membrane may decrease in the subsequent heat treatment, and the permeability may deteriorate.

< other Process >

In order to improve the film strength such as puncture strength, the film may be further stretched by about 5% to 80% in the longitudinal direction, the transverse direction, or both directions after being washed and dried.

On the other hand, in the present invention, the stretched film or the microporous film after stretching may be subjected to a heat setting treatment and/or a heat relaxation treatment. By the heat setting treatment and the heat relaxation treatment, a microporous membrane having stabilized crystallization, uniform sheet-like layer, large pore diameter and excellent strength can be produced. The heat-setting treatment is performed in a temperature range of not less than the crystal dispersion temperature and not more than the melting point of the polyolefin resin constituting the polyolefin microporous membrane. The heat setting treatment is performed by a tenter system, a roll system or a calender system.

As the thermal relaxation treatment method, for example, a method disclosed in Japanese patent laid-open No. 2002-256099 can be used.

Further, the stretched film or the microporous film may be subjected to a hydrophilization treatment according to other uses. Hydrophilization treatment may be performed by monomer grafting, surfactant treatment, corona discharge, or the like. Monomer grafting is preferably carried out after the crosslinking treatment.

In the case of the surfactant treatment, any of a nonionic surfactant, a cationic surfactant, an anionic surfactant and an amphoteric surfactant can be used, and a nonionic surfactant is preferable. The microporous membrane is immersed in a solution obtained by dissolving a surfactant in water or a lower alcohol such as methanol, ethanol, or isopropyl alcohol, or the solution is applied to the microporous membrane by a doctor blade method.

If necessary, at least one surface of the stretched film or the microporous film may be subjected to corona discharge treatment in an atmosphere of air, nitrogen, or a mixed gas of carbon dioxide and nitrogen.

The present invention also provides a separator for a nonaqueous electrolyte secondary battery using the polyolefin microporous film, and a nonaqueous electrolyte secondary battery using the separator for a nonaqueous electrolyte secondary battery. As described above, the polyolefin microporous membrane of the present invention has good temperature characteristics and shrinkage characteristics, and is excellent in the balance between strength and permeability. Therefore, by using such a microporous membrane, a highly safe separator for a nonaqueous electrolyte secondary battery having excellent shutdown characteristics, strength, and permeability can be provided, and a nonaqueous electrolyte secondary battery having high performance and excellent safety can be obtained as compared with the conventional ones.

Examples

Specific examples of the present invention will be described below with reference to examples, but the present invention is not limited thereto.

(measurement method)

1. Determination of the molecular weight distribution of polyolefins

The polyolefin was subjected to molecular weight distribution measurement (measurement of weight average molecular weight, molecular weight distribution, content of predetermined component, and the like) by high-temperature GPC. The measurement conditions were as follows.

The device comprises the following steps: high temperature GPC apparatus (equipment No. HT-GPC, manufactured by Polymer Laboratories, PL-220).

A detector: and a refractive index detector RI.

Protection of the column: shodex G-HT.

A chromatographic column: shodex HT806M (2 roots) (7.8 mm. times.30 cm, manufactured by Showa Denko K.K.).

Solvent: 1,2, 4-trichlorobenzene (TCB, Wako pure chemical industries, Ltd.) (0.1% BHT was added).

Flow rate: 1.0 mL/min.

Temperature of the column: 145 ℃.

Sample preparation: 5mL of a measurement solvent was added to 5mg of the sample, and the mixture was heated and stirred at 160 to 170 ℃ for about 30 minutes, and then the obtained solution was filtered through a metal filter (pore size: 0.5 μm).

Injection amount: 0.200 mL.

Standard sample: monodisperse polystyrene (manufactured by Tosoh).

Data processing: the TRC system GPC data processing system.

2. Film thickness

The thickness of the microporous membrane was measured at randomly selected MD positions using a contact thickness meter. At this MD position, the film thickness was measured at 5mm intervals over a distance of 30cm at a point along the TD (width) direction of the film. Then, the thickness of the sample was measured 5 times in the TD direction, and the arithmetic average value thereof was defined as the thickness of the sample.

3. Degree of air resistance

The film thickness was measured to be T by using a gas permeability meter (EGO-1T, manufactured by Asahi Seiki Kaisha)₁Measurement of gas resistance P of the microporous Membrane₁By the formula: p₂＝(P₁×16)/T₁The air resistance P was calculated when the film thickness was 16 μm₂。

4. Puncture strength

A needle having a diameter of 1mm and a spherical tip (radius of curvature R: 0.5mm) was inserted into the needle at a speed of 2 mm/sec so as to have an average film thickness T₁(μm) microporous membrane, to determine the maximum load L₁(load before penetration, unit: gf), passing through L₂＝(L₁×16)/T₁The puncture strength L at a film thickness of 16 μm was calculated by the following equation₂(gf)。

5. Porosity of the product

Regarding the porosity, the mass w of the microporous membrane is determined₁And the mass w of a pore-free film of the same size composed of the same polyolefin composition as the microporous film₂The porosity (%) - (w)₂-w₁)/w₂The equation of x 100.

Shrinkage temperature and shrinkage ratio in TD direction

A test piece having a length of 10mm (TD) x a width of 3Mm (MD) was stretched in the TD direction with a constant load (2gf) using a thermomechanical analyzer (TMA/SS 6600, manufactured by Seiko electronics Co., Ltd.), the temperature was raised from room temperature at a rate of 5 ℃/min, and the temperature at the inflection point of the sample length observed in the vicinity of the melting point was set as the shutdown shrinkage temperature in the TD direction. The percentage of shrinkage in the TD direction at the shutdown shrinkage temperature was calculated based on the length at room temperature, and the obtained value was defined as the shutdown shrinkage percentage. Similarly, the temperature at which the sample length is the smallest is set as the maximum shrinkage temperature in the TD direction, and the shrinkage rate (calculated based on room temperature) of the TD direction length at the maximum shrinkage temperature is set as the maximum shrinkage rate in the TD direction (see fig. 1). That is, the shrinkage rate of the TD direction length at the shutdown shrinkage temperature (shrinkage rate a) and the shrinkage rate of the TD direction length at the maximum shrinkage temperature (shrinkage rate B) are determined by the following equations, in which the TD direction length at the shutdown shrinkage temperature is represented by "dimension a", the TD direction length at the maximum shrinkage temperature is represented by "dimension B", and the TD direction length at room temperature is represented by "dimension C".

Shrinkage a { (dimension C) - (dimension a) } ÷ (dimension C) × 100

Shrinkage rate B { (dimension C) - (dimension B) } ÷ (dimension C) × 100

7. Impact test of battery

Cylindrical batteries were produced in the following order, and subjected to an impact test.

< preparation of Positive electrode >

LiCoO, a lithium cobalt composite oxide, as an active material₂92.2 mass% of each of flake graphite and acetylene black as conductive agents was 2.3 mass%, and 3.2 mass% of polyvinylidene fluoride (PVDF) as a binder was dispersed in N-methylpyrrolidone (NMP) to prepare a slurry. Coating quantity of 250g/m with active substance²The bulk density of the active material is 3.00g/cm³This slurry was applied to one surface of an aluminum foil having a thickness of 20 μm as a positive electrode current collector by a die coater. Then, the sheet was dried at 130 ℃ for 3 minutes, compression-molded by a roll press, and then cut into a tape shape having a width of about 57 mm.

< preparation of negative electrode >

96.9 mass% of artificial graphite as an active material, 1.4 mass% of an ammonium salt of carboxymethyl cellulose as a binder, and 1.7 mass% of styrene-butadiene copolymer latex were dispersed in purified water to prepare a slurry. Coating quantity of 106g/m with active material²The bulk density of the active material is 1.55g/cm³The slurry was applied to one surface of a copper foil having a thickness of 12 μm as a negative electrode current collector by a die coater. Then, the sheet was dried at 120 ℃ for 3 minutes, compression-molded by a roll press, and then cut into a tape shape having a width of about 58 mm.

< preparation of nonaqueous electrolyte solution >

LiPF as a solute was dissolved in a mixed solvent of ethylene carbonate/ethyl methyl carbonate (volume ratio) 1/2₆The concentration thereof was adjusted to 1.0 mol/l.

< separator >

The separators described in examples and comparative examples were cut into a 60mm strip shape.

< Battery Assembly >

the strip-shaped negative electrode, the separator, the strip-shaped positive electrode, and the separator were stacked in this order, and were spirally wound a plurality of times with a winding tension of 250fg, thereby preparing an electrode plate laminate. The cell plate laminate was housed in a stainless steel container having an outer diameter of 18mm and a height of 65mm, an aluminum tab led out from the positive electrode current collector was welded to the container lid terminal portion, and a nickel tab led out from the negative electrode current collector was welded to the container wall. Then, the container was dried at 80 ℃ for 12 hours under vacuum, and the nonaqueous electrolytic solution was poured into the container in an argon gas box and sealed.

< pretreatment >

After the assembled battery was constant-current charged to a voltage of 4.2V at a current value of 1/3C, constant-voltage charging of 4.2V was performed for 5 hours, and then discharging was performed at a current of 1/3C until a terminal voltage of 3.0V. Subsequently, the assembled battery was constant-current charged to a voltage of 4.2V at a current value of 1C, followed by constant-voltage charging at 4.2V for 2 hours, and then discharging at a current of 1C until a final voltage of 3.0V. Finally, after constant current charging to 4.2V at a current value of 1C, constant voltage charging of 4.2V was performed for 2 hours as a pretreatment.

< impact test >

After 20 batteries were produced by the above method, each battery was subjected to an impact test, and the impact resistance (safety) was evaluated based on the number of short-circuited batteries. First, the fabricated battery was heated at 105 ℃ for 1 hour, allowed to freely fall from a height of 2m, and then left to stand for 10 minutes. Then, the terminal voltage was measured, and a case where the terminal voltage was less than 90% before the test was determined to be "short-circuited state". Then, as a result of statistical measurement, the smaller the number of short-circuited batteries, the better the impact resistance was evaluated. The evaluation criteria are as follows.

The number of short-circuited batteries is 0-4 out of 20: excellent (excellent).

The short circuit condition of 5-10 out of 20: o (good).

The 20 short circuits exist in 11-14 cases: Δ (may).

Case of short circuit of 15 or more out of 20: x (impossible).

(example 1)

An ultrahigh-molecular-weight polyethylene (UHMWPE, weight-average molecular weight: 2.89X 10) was prepared as an ultrahigh-molecular-weight polyolefin⁶Molecular weight distribution (Mw/Mn): 5.28)15 weight percent and high density polyethylene (HDPE, weight average molecular weight: 5.72X 10⁵Molecular weight distribution: 4.81)85 weight percent of a polyethylene composition. When the total weight of the polyethylene composition was set to 100% by weight, the content of the polyethylene component having a molecular weight of 50 ten thousand or less was 62% by weight, and the content of the polyethylene component having a molecular weight of 100 ten thousand or more was 24% by weight. To 100 parts by mass of the resulting polyethylene composition, tetrakis [ methylene-3- (3, 5-di-t-butyl-4-hydroxyphenyl) -propionate ] was dry-blended]Methane 0.375 parts by mass to obtain a mixture.

30 parts by mass of the obtained mixture was charged into a strong kneading type twin-screw extruder (charged amount Q of polyethylene composition: 54kg/h), and 70 parts by mass of liquid paraffin was supplied from a side feeder of the twin-screw extruder, and melt kneading was performed at a temperature of 210 ℃ while keeping the screw rotation speed Ns at 180rpm (Q/Ns: 0.3kg/h/rpm) to prepare a polyethylene solution.

The obtained polyethylene solution was fed from a twin-screw extruder to a T die and extruded into a sheet-like molded body. The extruded molded article was cooled while being taken out by a cooling roll adjusted to 35 ℃ to form a gel sheet. Here, the contact surface of the cooling roll was set as the front surface, the non-contact surface was set as the back surface, the cooling rate of the front surface was 399 ℃/min, and the cooling rate of the back surface was 380 ℃/min. The obtained gel sheet was subjected to longitudinal stretching (MD stretching) at a stretching temperature of 115 ℃ in a roll system to a stretching ratio of 5 times, and then introduced into a tenter to perform horizontal stretching (TD stretching) at a stretching ratio of 6 times and a stretching temperature of 115 ℃.

The stretched film was fixed to a 20cm × 20cm aluminum frame plate, immersed in a cleaning bath (cleaning bath) of methylene chloride, and washed while shaking for 10 minutes to remove liquid paraffin, and then the washed film was air-dried at room temperature. Then, the film was heat-set at 125 ℃ for 10 minutes to produce a microporous polyolefin film having a thickness of 16 μm.

(example 2)

A polyolefin microporous membrane was produced in the same manner as in example 1, except that the composition ratio of the polyethylene composition was changed to 30 wt% for UHMWPE and 70 wt% for HDPE, and the resin concentration of the polyethylene solution was changed to 28.5 parts by mass for the mixture and 71.5 parts by mass for liquid paraffin. When the molecular weight distribution of the polyethylene composition was measured, the content of the polyethylene component having a molecular weight of 50 ten thousand or less was 59% by weight, and the content of the polyethylene component having a molecular weight of 100 ten thousand or more was 26% by weight.

(example 3)

A polyolefin microporous membrane was produced in the same manner as in example 2, except that the stretching temperature for MD stretching was 85 ℃.

(example 4)

A polyolefin microporous membrane was produced in the same manner as in example 1, except that the composition ratio of the polyethylene composition was changed to 40 weight percent for UHMWPE and 60 weight percent for HDPE, and the resin concentration of the polyethylene solution was changed to 25 parts by mass for the mixture and 75 parts by mass for liquid paraffin. When the molecular weight distribution of the polyethylene composition was measured, the content of the polyethylene component having a molecular weight of 50 ten thousand or less was 51% by weight, and the content of the polyethylene component having a molecular weight of 100 ten thousand or more was 35% by weight.

(example 5)

A polyolefin microporous membrane was produced in the same manner as in example 4, except that the MD stretching magnification was 7 times.

(example 6)

A polyolefin microporous membrane was produced in the same manner as in example 4, except that the MD stretching magnification was set to 9 times.

(example 7)

A polyolefin microporous membrane was produced in the same manner as in example 4, except that the MD stretching ratio was 7 times and the TD stretching ratio was 5 times.

(example 8)

A polyolefin microporous membrane was produced in the same manner as in example 4, except that the stretching ratio of MD stretching was 7 times and the stretching ratio of TD stretching was 7 times.

(example 9)

The weight-average molecular weight of the polyolefin is 1.6X 10⁶And an ultrahigh molecular weight polyethylene having a molecular weight distribution (Mw/Mn) of 5.3 were produced in the same manner as in example 8. When the molecular weight distribution of the polyethylene composition was measured, the content of the polyethylene component having a molecular weight of 50 ten thousand or less was 56% by weight, and the content of the polyethylene component having a molecular weight of 100 ten thousand or more was 29% by weight.

(example 10)

A polyolefin microporous membrane was produced in the same manner as in example 9, except that the resin concentration of the polyethylene solution was changed to 28.5 parts by mass in the mixture and 71.5 parts by mass in the liquid paraffin.

(example 11)

A microporous polyolefin membrane was produced in the same manner as in example 2, except that some conditions such as the stretching ratio and the stretching temperature were changed. Specifically, the conditions after the stretching step were changed as follows.

The molded article extruded from the T-die was cooled in the same manner as in example 2 while being drawn out by a cooling roll to form a gel sheet, and the obtained gel sheet was subjected to longitudinal stretching (MD stretching) at a stretching temperature of 115 ℃ in a roll system to a stretching ratio of 8, followed by introduction into a tenter and horizontal stretching (TD stretching) at a stretching ratio of 8 and a stretching temperature of 112 ℃.

The stretched film was washed in a washing tank with dichloromethane adjusted to 25 ℃ to remove liquid paraffin. The washed film was dried in a drying oven adjusted to 60 ℃, stretched 1.4-fold in the TD direction in a tenter at 131 ℃, then relaxed to 1.3-fold finally, and subjected to heat setting treatment for 40 seconds, thereby obtaining a polyolefin microporous film having a thickness of 12 μm.

Comparative example 1

A polyolefin microporous membrane was produced in the same manner as in example 2, except that the gel sheet was simultaneously biaxially stretched at a stretching temperature of 115 ℃, a stretching ratio in the MD of 5 times, and a stretching ratio in the TD of 7 times, instead of sequential stretching.

Comparative example 2

A polyolefin microporous membrane was produced in the same manner as in comparative example 1, except that the TD stretching ratio was 6 times.

Comparative example 3

A polyolefin microporous membrane was produced in the same manner as in example 8, except that the composition ratio of the polyethylene composition was changed to 10 weight percent for UHMWPE and 90 weight percent for HDPE, and the resin concentration of the polyethylene solution was changed to 30 parts by mass for the mixture and 70 parts by mass for liquid paraffin. When the molecular weight distribution of the polyethylene composition was measured, the content of the polyethylene component having a molecular weight of 50 ten thousand or less was 64% by weight, and the content of the polyethylene component having a molecular weight of 100 ten thousand or more was 21% by weight.

Comparative example 4

A polyolefin microporous membrane was produced in the same manner as in example 6, except that the composition ratio of the polyethylene composition was changed to 100% by weight of HDPE, and the resin concentration of the polyethylene solution was changed to 40 parts by mass of the mixture and 60 parts by mass of liquid paraffin. When the molecular weight distribution of the polyethylene composition was measured, the content of the polyethylene component having a molecular weight of 50 ten thousand or less was 68 wt%, and the content of the polyethylene component having a molecular weight of 100 ten thousand or more was 16 wt%.

Comparative example 5

In an attempt to produce a polyolefin microporous membrane in the same manner as in example 1 except that the composition ratio of the polyethylene composition was changed to 60% by weight for PE1 and 40% by weight for PE2, the pressure in the step was increased, and thus stable membrane formation was not performed, and a microporous membrane could not be obtained. When the molecular weight distribution of the polyethylene composition was measured, the content of the polyethylene component having a molecular weight of 50 ten thousand or less was 43% by weight, and the content of the polyethylene component having a molecular weight of 100 ten thousand or more was 42% by weight.

The results of the above examples and comparative examples are shown in tables 1 and 2.

[ Table 1]

[ Table 2]

[ Industrial Applicability ]

The polyolefin microporous film of the present invention is suitably used for a separator for a nonaqueous electrolyte secondary battery.

Claims

1. a polyolefin microporous membrane characterized in that the difference between the maximum shrinkage temperature in the TD direction and the shutdown shrinkage temperature measured by TMA is 7.2 ℃ or more, the difference between the maximum shrinkage rate in the TD direction and the shutdown shrinkage rate is less than 25%, the puncture strength is 400gf or more when the membrane thickness is 16 μm, the ratio of the puncture strength to the air resistance is 2.0 to 4.0gf/(sec/100cc) when the membrane thickness is 16 μm,

Weight average molecular weight 5.0X 10⁵The polyolefin content is 63 wt% or less, and the weight-average molecular weight is 1.0X 10⁶The content of the above polyolefin is 21% by weight or more,

Weight average molecular weight 1.0X 10⁶The amount of the above ultrahigh molecular weight polyolefin is 15 to 45% by weight.

2. The polyolefin microporous membrane according to claim 1, wherein the porosity is 45% or more.

3. A method for producing a polyolefin microporous membrane according to claim 1 or 2, comprising the following steps (a) to (f):

(a) For the weight average molecular weight of 1.0X 10⁶A step of melt-kneading the polyolefin resin of the ultra-high molecular weight polyethylene and the plasticizer to prepare a polyolefin solution;

(b) Extruding the polyolefin solution obtained in the step (a) by an extruder to form an extrudate, cooling the extrudate, and forming a gel sheet;

(c) Stretching the sheet obtained in the step (b) in a machine direction;

(d) a step of stretching the sheet obtained in the step (c) in a direction perpendicular to the machine direction, which is a horizontal direction, continuously to the step (c);

(e) A step of extracting a plasticizer from the stretched film obtained in the step (d);

(f) and (e) drying the film obtained in step (e).

4. A separator for a nonaqueous electrolyte secondary battery, comprising the polyolefin microporous membrane according to claim 1 or 2.

5. A nonaqueous electrolyte secondary battery comprising the separator for a nonaqueous electrolyte secondary battery according to claim 4.